WO2012074642A1 - Procédés et dispositifs destinés à commander une machine à touffeter destinée à former une moquette touffetée - Google Patents

Procédés et dispositifs destinés à commander une machine à touffeter destinée à former une moquette touffetée Download PDF

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Publication number
WO2012074642A1
WO2012074642A1 PCT/US2011/058286 US2011058286W WO2012074642A1 WO 2012074642 A1 WO2012074642 A1 WO 2012074642A1 US 2011058286 W US2011058286 W US 2011058286W WO 2012074642 A1 WO2012074642 A1 WO 2012074642A1
Authority
WO
WIPO (PCT)
Prior art keywords
yarn feed
yarn
feed
yarns
control system
Prior art date
Application number
PCT/US2011/058286
Other languages
English (en)
Inventor
Neil Vaughan
Mark Honeycutt
Original Assignee
Shaw Industries Group, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shaw Industries Group, Inc. filed Critical Shaw Industries Group, Inc.
Priority to CN201180054899.XA priority Critical patent/CN103221601B/zh
Priority to EP11844649.1A priority patent/EP2633112B1/fr
Priority to AU2011337101A priority patent/AU2011337101B2/en
Publication of WO2012074642A1 publication Critical patent/WO2012074642A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C5/00—Embroidering machines with arrangements for automatic control of a series of individual steps
    • D05C5/04—Embroidering machines with arrangements for automatic control of a series of individual steps by input of recorded information, e.g. on perforated tape
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/16—Arrangements or devices for manipulating threads
    • D05C15/18—Thread feeding or tensioning arrangements
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05B—SEWING
    • D05B19/00—Programme-controlled sewing machines
    • D05B19/02—Sewing machines having electronic memory or microprocessor control unit
    • D05B19/04—Sewing machines having electronic memory or microprocessor control unit characterised by memory aspects
    • D05B19/08—Arrangements for inputting stitch or pattern data to memory ; Editing stitch or pattern data
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/26—Tufting machines with provision for producing patterns

Definitions

  • This invention relates to a tufting machine for forming tufted carpet. More specifically, this invention relates to a control system for a tufting machine for forming patterned tufted articles.
  • the invention relates to a control system for a tufting machine of the type having a plurality of needles for forming tufted carpet.
  • the tufted carpet can be formed from tufts of yarn having different heights relative to a backing material.
  • the tufts can be arranged so that patterns are apparent on the face of the carpet.
  • control system for the tufting machine comprises a system controller in communication with the tufting machine for controlling operation of the tufting machine.
  • system controller can be in communication with a plurality of yarn feed controllers for controlling operation of yarn feed motors which supply yarn from a source of yarn to the tufting machine.
  • the system controller can be programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted.
  • the system controller can be programmable to control the operation of the respective yarn feed controllers to feed yarns to the needles for each selected stitch to be tufted according to the respective predetermined yarn feed profile.
  • substantially the same feed length of yarn can be used from each of the plurality of yarns.
  • each predetermined yarn feed profile can be programmed by determining a base yarn feed value for each stitch of the yarn for each pattern repeat of the programmed pattern.
  • the yarn feed profile for at least one stitch for each pattern repeat can be varied from the base yarn feed value.
  • the system controller can be programmable to enable input of a plurality of N predetermined yarn feed profiles for selected stitches of the programmed pattern.
  • the system controller can index each of the plurality of N predetermined yarn feed profiles to operatively control a different yarn feed controller.
  • the system controller can control the operation of the respective yarn feed controllers to feed yarns to the plurality of needles for each selected stitch to be tufted according to the selected predetermined yarn feed profile.
  • substantially the same feed length of yarn can be used from each of the plurality of yarns.
  • each predetermined yarn feed profile can be programmed by determining a base yarn feed value for each stitch of the yarn for each pattern repeat of the programmed pattern.
  • the yarn feed profile for at least one stitch for each pattern repeat can be varied from the base yarn feed value.
  • FIG. 1 is a schematic view of the control system for a tufting machine in accordance with one embodiment of this invention, the control system showing a source of yarns in communication with a plurality of yarn feed motors and a coupled plurality yarn feed controllers.
  • a system controller is in communication with the plurality yarn feed controllers to effect control of the plurality of yarn feed motors.
  • FIG. 2 is a schematic view of the control system for a tufting machine in accordance with one embodiment of this invention, showing a yarn accumulator system disposed between the source of yarns and the plurality of yarn feed motors.
  • FIG. 3 is an exemplary pattern for input into the control system of the tufting machine for the production of carpet having a varied pile height in which at least two predetermined yarn feed profiles of a plurality of predetermined yarn feed profiles are different.
  • substantially the same feed length of yarn is used for each of the plurality of yarns in each repeat of the programmed pattern.
  • FIGS. 4A and 4B is an exemplary pattern for input into the control system of the tufting machine for the production of carpet having a varied pile height in which at least two predetermined yarn feed profiles of a plurality of predetermined yarn feed profiles are different.
  • the respective relative high/low feed profiles for each respective needle is shown for each pattern repeat (illustrating an exemplary one needle shift for each repeat).
  • Ranges can be expressed herein as from “about” one particular value, and/or to "about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
  • the application relates to a tufting machine for forming tufted carpet.
  • the tufting machine forms tufted carpet on a backing material moving in a machine direction through the tufting machine.
  • the backing material can have a top surface.
  • the tufting machine can comprise means for inserting loops of yarn into the backing material.
  • the loops of yarn can be inserted into the backing material to form sequential substantially linear rows of yarn tufts thereon the backing material.
  • the sequential substantially linear rows of yarn tufts thereon the backing material can be substantially transverse to the machine direction. It is contemplated that the sequential substantially linear rows of yarn tufts thereon the backing material can be spaced substantially equally apart in the machine direction.
  • the means for inserting loops of yarn into the backing material can comprise a needle bar having a plurality of needles mounted thereon.
  • the means for inserting loops of yarn into the backing material can comprise a plurality of needles carrying a plurality of yarns into the backing material as the backing material passes through the tufting machine at a desired rate.
  • the means for inserting loops of yarn into the backing material can further comprise a series of loopers adapted to engage the needles for forming loop pile tufts.
  • any means known in the art for inserting loops of yarn into a carpet backing can be used to insert loops of yarn into the backing material.
  • each yarn tuft can project therefrom the top surface of the backing material a predetermined height.
  • each yarn tuft can project therefrom the top surface of the backing material a predetermined height such that a pattern or a desired appearance is formed on the face of the carpet.
  • the predetermined height can vary or be substantially the same from tuft to tuft so that a pattern is formed on the face of the carpet.
  • each yarn tuft can be a cut pile tuft, a loop tuft, or any variation thereof.
  • a control system 100 for a tufting machine 2 for forming patterned tufted articles is provided.
  • the control system can comprise at least one of a source of yarns 4, a plurality of yarn feed motors 6, a plurality of yarn feed controllers 8, and a system controller 12 in communication with the tufting machine.
  • a tufting machine in communication with at least one of a source of yarns, a plurality of yarn feed motors, a plurality of yarn feed controllers, and a system controller is known in the art and it is contemplate that any such conventional tufting system can be used with the process and method of the present invention.
  • the source of yarns 4 can comprise a plurality of yarns, such as for example and without limitation, at least one creel or at least one beam.
  • each yarn feed motor of the plurality of yarn feed motors 6 can be in communication with one yarn from the source of yarns and one needle of the plurality of needles of the tufting machine.
  • each yarn feed controller 8 of the plurality of yarn feed controllers can be coupled to a respective yarn feed motor for controlling the amount of yarn being supplied by the respective yarn feed motor to a respective needle of the tufting machine.
  • each yarn feed controller of the plurality of yarn feed controllers can provide yarn to a
  • each yarn feed controller of the plurality of yarn feed controllers can further comprise means for selectively adjusting the yarn feed rate.
  • the system controller 12 can be configured for controlling operation of the tufting machine.
  • the system controller can be configured for controlling operation of the yarn feed controllers for controlling operation of the yarn feed motors.
  • the control system can comprise a processor coupled to each yarn feed controller of the plurality of yarn feed controllers.
  • the processor of the control system can be configured to control the respective yarn feed rate of each yarn feed controller of the plurality of yarn feed controllers in response to a predetermined yarn feed profile, described more fully below.
  • the processor can be any processing element known in the art, such as, without limitation, a personal computer or a server computer.
  • the processor can comprise any of a number of processing devices, systems or the like that are capable of operating in accordance with the embodiments of the invention. It is contemplated that the processor can be in communication with a memory that stores content, data, or the like. The memory can also store software applications, instructions, or the like for the processor to perform steps associated with varying the predetermined yarn feed profiles, as described herein. It is further contemplated that the processor can be connected to at least one interface or other means for displaying, transmitting, and/or receiving data, content, or the like.
  • the interface can include at least one communication interface or other means for transmitting and/or receiving data, content, or the like, as well as at least one user interface that can include a display and/or a user input interface.
  • the user input interface can comprise any of a number of devices allowing the processor to receive data from a user, such as a keypad, a touch display, a joystick or other input device.
  • the control system can be configured to signal at least one yarn feed controller of the plurality of yarn feed controllers to change its yarn feed rate to a selected yarn feed rate.
  • the system controller 12 can be programmable to enable input of a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted.
  • the system controller can further be programmable to control the operation of the respective yarn feed controllers to feed yarns to the plurality of needles for each selected stitch to be tufted at a yarn feed rate according to the predetermined yarn feed profile.
  • the plurality of predetermined yarn feed profiles can indicate to the each of the yarn feed controllers how long to activate the respective yarn feed motors so that the yarn feed motors supply yarn to the backing material at a desired feed control rate, and so that the face of the carpet has a plurality of tufts having desired tuft heights.
  • each predetermined yam feed profiles of the plurality of predetermined yam feed profiles can be the same.
  • at least two predetermined yam feed profiles of the plurality of predetermined yam feed profiles can be different.
  • an average feed control rate of the plurality of predetermined yam feed profiles can be calculated by averaging a feed control rate for each yam of a respective yam feed profile.
  • substantially the same feed length of yam can be used for each of the plurality of yams.
  • the feed length of yam can vary between each of the plurality of yams by less than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 12%, 14%, 16%, 18%, 20%, 25%, 30%, 35%, 40%, 45%, or 50%.
  • a base yam feed value in order to program each predetermined yam feed profile, can be determined for each stitch of the yam for each pattem repeat of the programmed pattem.
  • the base yam feed value can represent the amount of yam required to make each stitch such that the resultant tuft has a desired height.
  • the yam feed profile can be varied from the base yam feed value for at least one stitch of the yam for each pattem repeat.
  • the amount of variation from the base yam feed value can be less than 0.3 inches, less than 0.2 inches, less than 0.1 inches or less than 0.05 inches.
  • the amount of variation can be a positive variation in yam feed length from the base yam feed value, such that an actual yam feed length is greater than the base yam feed value.
  • the amount of variation can be a negative variation in yam feed length from the base yam feed value, such that the actual yam feed length is less than the base yam feed value.
  • the process of programming each predetermined yard feed profile can be repeated for each predetermined yam feed profile until the feed length of yam per pattem repeat is substantially the same for the plurality of predetermined yam feed rates.
  • the process of programming each predetermined yard feed profile can be repeated for each predetermined yam feed profile until the feed length of yam per pattem repeat varies between each of the plurality of yam feed rates by less than about 1%, 2%, 3%,
  • the first yarn feed profile can be decreased by 0.05 inches for twenty stitches for each pattern repeat in order to make the feed length of yarn per pattern repeat substantially the same for the plurality of predetermined yarn feed rates.
  • the first yarn feed profile can be decreased by 0.02 inches for 25 stitches for each pattern repeat and the second yarn feed profile can be increased by 0.02 inches for 25 stitches for each pattern repeat in order to make the feed length of yarn per pattern repeat substantially the same for the plurality of predetermined yarn feed rates.
  • various combinations of decreases to the first yarn feed profile and/or increases to the second yarn feed profile can cause substantially the same feed length of yarn to be used for each of the plurality of yarns.
  • the amount to vary a yarn feed profile from the base yarn feed value can be selected based on the number of stitches per pattern repeat, i.e., the more stitches per pattern repeat, the greater number of stitches to spread the change to the base yarn feed value, so that the change per stitch is less or not noticeable.
  • each white square denotes a Low feed rate profile and each black square denotes a Hi feed rate profile for each of the needle/stitch combinations in the exemplary 10X10 pattern.
  • substantially the same feed length of yam is used for each of the plurality of yams in each repeat of the programmed pattern.
  • variations in the new low of the respective pattern are made such that the yam length for each of the yams used in the entirety of the 10X10 pattern are substantially the same.
  • control system 100 can further comprise a drive roll 9 in communication with the source of yams.
  • the drive roll can be configured to draw the plurality of yams from the source of yams at a substantially constant yam feed rate.
  • the substantially constant yam feed rate can be equal to the average feed control rate of the plurality of yam feed profiles.
  • the yam feed rate can selectively be less than, equal to, or greater than the average feed control rate of the plurality of predetermined yam feed profiles.
  • the drive roll can be positioned between the source of yams and the plurality of yam feed motors.
  • control system 100 can further comprise a yam accumulator system 20 that is in communication with the source of yams.
  • the yam accumulator system can be disposed between the source of yams and the plurality of yam feed motors.
  • the yam accumulator system can be positioned between the drive roll and the plurality of yam feed motors.
  • the yam accumulator system can comprise a plurality of weight elements 22 suspended above the ground by the respective yams.
  • each weight element 22 can have a lumen extending therethrough that is configured, or otherwise sized and shaped to allow for the free passage of one yam.
  • each yam being fed to the tufting machine passes through one weight element 22.
  • the yarn accumulator system can further comprise a pair of opposed spaced bars or rollers 24 that are elevated above the ground.
  • each yarn being fed to the tufting machine passes over one of the spaced bars or rollers through one weight element 22 and subsequently over the other spaced bars or rollers.
  • yarn can accumulate upstream of the respective yarn motors at an unequal rate.
  • each yarn will be drawn downward due to the gravitational action of the weight element 22 as excess yarn accumulates over the programmed pattern and will we drawn upward due to the increased feed rate that is necessitated by the programmed pattern.
  • the use of such a yarn accumulator system 22 can help to avoid unnecessary and undesired tangles in the plurality of yarns.
  • such a yarn accumulator system 22 can be used in conjunction with yarns being supplied by at least one creel or at least one beam.
  • system controller 12 can be programmable to enable input of a plurality of N predetermined yarn feed profiles for selected stitches of a
  • system controller can further be programmable to index each of the plurality of N predetermined yarn feed profiles to operatively control a different yarn feed controller after every X pattern repeat.
  • system controller can further be programmable to control the operation of the respective yarn feed controllers to feed yarns to the plurality of needles for each selected stitch to be tufted according to the predetermined yarn feed profile. In this aspect, after (N ⁇ X) repeats of the pattern repeat, substantially the same feed length of yarn can be used from each of the plurality of yarns.
  • the feed length of yarn can vary between each of the plurality of yarns by less than about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 12%, 14%, 16%, 18%, 20%, 25%, 30%, 35%, 40%), 45%), or 50%).
  • at least two predetermined yarn feed profiles of the plurality of N predetermined yarn feed profiles can be different.
  • the yarn feed profile could index by one so that a yarn feed profile is associated with an adjacent yarn feed controller for the fifth pattern repeat.
  • substantially the same feed length of yarn can be used from each of the plurality of yarns.
  • the pattern repeat can be repeated N times for N predetermined yarn feed profiles.
  • Each yarn feed controller can be controlled by a different one of the N predetermined yarn feed profiles for each of the N respective pattern repeats.
  • each yarn feed controller uses each one of the N predetermined yarn feed profiles.
  • each of the 5 predetermined yarn feed profiles can be indexed at the end of the pattern repeat to operatively control a yarn feed controller that has not previously been controlled by that particular yarn feed profile.
  • each yarn feed controller can have been controlled by each one of the 5 predetermined yarn feed profiles, and substantially the same feed length of yarn can be used from each of the plurality of yarns.
  • the pattern repeat can be repeated N ⁇ X times for N predetermined yarn feed profiles.
  • a pattern tufted article can be formed by determining a plurality of predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted.
  • a base yarn feed value can be determined for each stitch of the yarn for each pattern repeat of the programmed pattern.
  • the base yarn feed value for at least one stitch of the yarn for each pattern repeat can be modified.
  • modification from the base yarn feed value for at least one stitch for each pattern repeat can continue until the feed length of yarn per pattern repeat is substantially the same for each of the plurality of predetermined yarn feed profiles.
  • yarns from the plurality of yarns can be fed to the tufting machine at a predetermined yarn feed rates according to the respective yarn feed profile for each stitch of the pattern until the pattern is completed. Because the base yarn feed value can be modified for at least one stitch of the yarn for each pattern repeat until the feed length of yarn per pattern repeat is substantially the same for each plurality of predetermined yarn feed profiles, for each repeat of the programmed pattern, substantially the same feed length of yarn can be used for each of the plurality of yarns.
  • a patterned tufted article in operation, can be formed by determining a plurality of N predetermined yarn feed profiles for selected stitches of a programmed pattern to be tufted.
  • each of the plurality of predetermined yarn feed profiles can be indexed to operatively control a different yarn feed controller 8.
  • yarns can be fed from a plurality of yarn feed controllers at the selected respective predetermined yarn feed profiles for each stitch of the pattern until the pattern is completed. Because the yarn feed profiles index after every X pattern repeats, after N ⁇ X pattern repeats, substantially the same feed length of yarn can be used for each of the plurality of yarns.
  • each white square denotes a Low feed rate profile and each black square denotes a Hi feed rate profile for each of the needle/stitch combinations in the exemplary pattern that is repeated 10 times.
  • the pattern is repeated 10 times but is shifted one needle upon each sequential repeat of the pattern.
  • substantially the same feed length of yarn is used for each of the plurality of yarns will be used.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)

Abstract

La présente invention concerne un système de commande pour une machine à touffeter configurée pour former une moquette touffetée. La machine à touffeter peut présenter un dispositif de commande de système en communication avec la machine à touffeter et avec une pluralité de dispositifs de commande d'alimentation en fil destinés à commander le fonctionnement de moteurs d'alimentation en fil configurés pour fournir un fil d'une source de fil à la machine à touffeter. Le dispositif de commande de système peut être programmé pour permettre l'entrée d'une pluralité de profils d'alimentation en fil prédéterminés pour les mailles sélectionnées d'un modèle programmé destinées à être touffetées, de telle sorte que, bien qu'au moins deux des profils d'alimentation en fil prédéterminés puissent être différents, sensiblement la même longueur d'alimentation en fil soit utilisée à partir de chaque fil de la pluralité de fils.
PCT/US2011/058286 2010-10-28 2011-10-28 Procédés et dispositifs destinés à commander une machine à touffeter destinée à former une moquette touffetée WO2012074642A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201180054899.XA CN103221601B (zh) 2010-10-28 2011-10-28 用于控制形成簇绒地毯所用的簇绒机的方法和装置
EP11844649.1A EP2633112B1 (fr) 2010-10-28 2011-10-28 Procédé et dispositif destinés à commander une machine à touffeter destinée à former une moquette touffetée
AU2011337101A AU2011337101B2 (en) 2010-10-28 2011-10-28 Methods and devices for controlling a tufting machine for forming tufted carpet

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US40760410P 2010-10-28 2010-10-28
US61/407,604 2010-10-28

Publications (1)

Publication Number Publication Date
WO2012074642A1 true WO2012074642A1 (fr) 2012-06-07

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2011/058286 WO2012074642A1 (fr) 2010-10-28 2011-10-28 Procédés et dispositifs destinés à commander une machine à touffeter destinée à former une moquette touffetée

Country Status (5)

Country Link
US (5) US8430043B2 (fr)
EP (1) EP2633112B1 (fr)
CN (1) CN103221601B (fr)
AU (1) AU2011337101B2 (fr)
WO (1) WO2012074642A1 (fr)

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US9334596B2 (en) 2010-10-28 2016-05-10 Columbia Insurance Company Methods and devices for controlling a tufting machine for forming tufted carpet

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EP3004446B1 (fr) 2013-05-29 2018-06-27 Card-Monroe Corporation Système d'entraînement de machine à touffeter
CN103710915B (zh) * 2014-01-02 2015-04-08 东华大学 离合器喂纱机构分时控制喂纱实现灵活控制喂纱量方法
CN104131426B (zh) * 2014-08-22 2016-05-11 威海市山花地毯集团有限公司 簇绒地毯织机上线的自动控制方法
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WO2017214520A1 (fr) 2016-06-09 2017-12-14 Shaw Industries Group, Inc. Articles tuftés structurés, leurs systèmes et procédés de fabrication
EP3348692A1 (fr) * 2017-01-12 2018-07-18 NV Michel van de Wiele Machine de tufting, procédé de tufting d'un tissu et tissu touffeté
GB201720794D0 (en) * 2017-12-13 2018-01-24 Michel Van De Wiele An individual needle control tufting machine
EP3877580A4 (fr) * 2018-11-09 2022-08-17 Tuftco Corporation Cantre comportant un système intégré de distribution et de commande de fil
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US10081896B2 (en) 2010-10-28 2018-09-25 Columbia Insurance Company Methods and devices for controlling a tufting machine for forming tufted carpet
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US20170002489A1 (en) 2017-01-05
US20190169775A1 (en) 2019-06-06
CN103221601A (zh) 2013-07-24
AU2011337101A1 (en) 2013-05-23
EP2633112A4 (fr) 2015-10-21
AU2011337101B2 (en) 2015-06-04
US20120137944A1 (en) 2012-06-07
US20150007760A1 (en) 2015-01-08
CN103221601B (zh) 2014-10-29
US20130340660A1 (en) 2013-12-26
EP2633112A1 (fr) 2013-09-04
US10767294B2 (en) 2020-09-08
US8770122B2 (en) 2014-07-08
US8430043B2 (en) 2013-04-30
US9334596B2 (en) 2016-05-10
US10081896B2 (en) 2018-09-25
EP2633112B1 (fr) 2018-02-21

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